Vehicle accessory system

ABSTRACT

A mirror assembly includes a reflective element portion and a molded portion formed of a multi-void, lightweight structure. The multi-void, lightweight structure may be formed by injecting a gas into an injection mold while the molded portion is being molded, resulting in a multi-void aerated molded structure having multiple-voids introduced during the molding step. A window assembly for a vehicle may include an outer frame portion, an inner frame portion hingedly attached to the outer frame portion, and at least one sealing element established along a sealing portion of the outer and/or inner frame portions. The outer frame portion may be pivoted relative to the inner frame portion and about the hinge portions to a closed position. The outer frame portion may be connected to the inner frame portion when in the closed position to secure the at least one sealing element therebetween.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a division of U.S. patent application Ser.No. 11/768,260, filed Jun. 26, 2007, now U.S. Pat. No. 7,712,809, whichis a continuation of U.S. patent application Ser. No. 11/289,092, filedNov. 29, 2005, now U.S. Pat. No. 7,234,756, which is a continuation ofU.S. patent application Ser. No. 10/727,731, filed Dec. 3, 2003, nowU.S. Pat. No. 6,969,101, which is a division of U.S. patent applicationSer. No. 09/679,997, filed Oct. 5, 2000 by Lynam et al. for EXTERIORACCESSORY MODULE FOR VEHICULAR MODULAR DOOR, now U.S. Pat. No.6,669,267, which claims priority from U.S. Provisional Applications,Ser. No. 60/159,661, filed Oct. 15, 1999 by Lynam, and Ser. No.60/215,324, filed Jun. 30, 2000 by Whitehead et al., which are allhereby incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

This invention relates generally to vehicle door assemblies and, moreparticularly, to an exterior accessory module, such as an exteriorrearview mirror and/or door handle assembly, which is mountable on adoor for a vehicle.

Exterior rearview mirrors are mounted at one or both sides of a vehicleto provide a driver of the vehicle with a view rearwardly and sidewardlyof the vehicle. The mirror assemblies may comprise a mirror or headportion and a mounting portion, which is secured to the side of thevehicle. The head portion may be movable to break away from the mountingportion and fold along the side of the vehicle, and may even be a powerfolding mirror assembly which is foldable along the side of the vehiclein response to a control within the vehicle.

Typically, mirror manufacturers provide the complete mirror assembly,including the head and mounting portions, to the vehicle assembly plant.The mirror assembly may also be painted or colored by the mirrormanufacturer, in order to avoid masking concerns at the vehicle assemblyplant. The mirror assembly is attached to the side of the door or to atrim piece or sail secured alongside the door or window. The mirrorassembly is installed to the door panel of the vehicle door at thevehicle assembly plant as the body of the vehicle travels along theassembly line.

Handles for the doors are also typically provided by the doormanufacturer and are specific to each particular door, depending on thecolor and/or style of the door. The handles are installed to the doorframe along with the external skin or outer cover of the door. Becausethe styles and colors of the handles may vary between applications,especially if the handle is molded in color to match a paint color thatwill be painted on the door at the vehicle assembly plant, this resultsin additional part numbers for each door assembly having a differenthandle style and/or color, even though the internal door frame and/orunpainted external covers of the doors may be common parts.

Recently, vehicle manufacturers have desired modular door assemblies tobe assembled remotely from the vehicle assembly line and provided to thevehicle assembly plant as a single unit. The modular doors comprise thedoor frame, door body and door panels, and preferably include some orall of the accessories for the doors, such as the handle and lockmechanisms, windows and window mechanisms, speakers, lights, regulators,hinge components, accessory controls or switches, such as controls foradjusting windows, locks, seats, mirrors, cabin temperature settings andthe like, trim pieces and exterior mirrors and the like. It is desirablefor the modular door manufacturer to supply a variety of door andvehicle models and designs using a common door frame or chassis. Thevarious components and panels are typically secured about the door frameto complete the door assembly. The modular doors are shipped to thevehicle assembly plant as a single unit and installed to the vehiclebody on the assembly line. This allows a single manufacturer tomanufacture the door module and requires less operator processes in thevehicle assembly plant.

Although the modular doors provide significant benefits to the vehiclemanufacturer, exterior mirror assemblies have heretofore presentedparticular problems with the modular door approach. This is becauseexterior mirrors may protrude significantly outwardly from the side ofthe modular door, thus causing difficulties in packaging and shippingthe modular doors to the assembly line. Furthermore, the mirror headportions and also the mounting portions are typically painted by themirror manufacturer before installing the mirror assembly to the vehiclein order to avoid masking concerns.

Additional issues arise when mirror assemblies are provided with variousoptional accessories, such as exterior temperature sensors, securitylights, motors or actuators for adjusting the reflector and/or thehousing of the mirror relative to the vehicle, and the like. Theadditional options within the mirror assemblies lead to further partsproliferation of the modular doors, since each different mirror assemblyor option associated therewith requires each modular door upon which itis installed to have a separate part number or code for the vehicleassembly plant. This number is then different from the other modulardoors shipped to the assembly plant, which may otherwise besubstantially identical in construction.

Many automobile manufacturers today prefer to assemble “skeletons” ofthe vehicle (i.e. the structural frame of the doors and body), and addthe interior and exterior components to the frame as the frame movesalong the assembly line. Typically, the door frames of the vehicle arestamped and installed to the vehicle as part of the “body in white” ofthe vehicle. The trim, glass, and other interior and exterior componentsare added later as the vehicle proceeds down the assembly line. However,it is difficult to add many of the components to the doors, since thecomponents are typically installed from the interior of the vehicle.Some doors receive an interior modular cassette on their interior sides.However, the cassettes include interior components only and may includespeakers, window regulators, window crank mechanisms, motors, shields orthe like. In some cases, due to the space constraints within the vehicleand access to the components of the doors, the doors are removed fromthe vehicle after painting, in order to facilitate assembly of thedoors, and then reinstalled to the respective vehicle further down theassembly line. This is an expensive and labor intensive process sincethe door must be installed to the vehicle twice. Further, the doorassemblies then require a separate conveyor assembly line to move thedoors through the assembly stations apart from the vehicle.

Additionally, the upper structural frame around the window, and the doorbody frame, and maybe even the exterior metal of the door, are oftenpart of a unibody construction of the door, whereby the door body frameand window frame are formed from a single stamped part. The entire doorand window frame is then mounted on the vehicle for assembly of theaccessories and panels thereto. The installation of the window guidesand/or seals is typically performed from inside the vehicle, therebymaking the process difficult, due to space constraints and access to thecomponents. Often, even the exterior mirror is secured to the door viafasteners from the interior side of the door. Additionally, the unibodyconstruction of the doors is expensive to make or stamp as a singleitem.

Therefore, there is a need in the art for an improved process ofassembling vehicle doors at the vehicle assembly plant or remotetherefrom. The process should allow easy installation of variousexterior accessories to a common frame, in order to avoid proliferationof parts within the vehicle or door assembly plant.

SUMMARY OF THE INVENTION

The present invention is intended to provide an exterior attachment oraccessory module or sub-module or sub-assembly for a vehicle door whichmay comprise an exterior rearview mirror, a cap assembly, which mayfurther include an exterior mirror body and/or a door handle, a windowframe, window seals, and/or a movable window, fixed window and/oradjustable vent window. The exterior accessory module or assembly iseasily mountable to an exterior mirror body mount that is on an exteriorside of a door assembly or to a frame of a door assembly, such that theexterior mirror and/or cap assembly may be mounted to the door assemblyat the vehicle assembly plant or elsewhere.

According to an aspect of the present invention, a modular door systemfor a vehicle is remotely assembled from a vehicle assembly plant. Themodular door preferably includes a window, at least one hinge component,a door frame, a door handle and lock mechanism, and an exterior mirrorbody mount at an exterior side of the door assembly for mounting anexterior mirror body to the modular door assembly. The mirror body mountincludes a first connecting portion which is connectable to acorresponding second connecting portion on the exterior mirror body, inorder to secure the exterior mirror body to the modular door.Preferably, the first connecting portion includes an electricalconnector for providing electrical connection to at least one electronicaccessory within the exterior mirror body.

Preferably, the system includes an exterior mirror connecting assembly,which includes a first connecting portion at the exterior mirror bodymount and a second connecting portion at the exterior mirror body. Thefirst connecting portion is connectable to the second connecting portionto positively secure the exterior mirror body to the exterior body mountof the door assembly from the exterior side of the door assembly.

According to another aspect of the present invention, an exterior mirrorbody assembly is mountable to a modular door. The modular door isremotely assembled from a vehicle assembly line and preferably includesa window, at least one hinge component, a door handle and lockmechanism, and a mirror body mount having a first connecting portion.The exterior mirror body assembly comprises a mirror housing, areflective element adjustably retained within the mirror housing, and asecond connecting portion. The second connecting portion is connectableto the first connecting portion to secure the exterior mirror body tothe modular door. Preferably, the exterior mirror body assembly ismountable to the modular door on the vehicle assembly line. Preferably,the first and second connecting portions include correspondingelectrical connectors for electronically connecting at least oneelectronic accessory of the exterior mirror body assembly to a vehiclewiring.

According to another aspect of the present invention, a vehicularmodular door system for a vehicle comprises a door assembly forattaching to the vehicle and a cap assembly, which includes at least aportion of an exterior panel of the vehicle door. The door assemblyincludes a door frame, an external panel, at least one hinge member anda latch mechanism for releasably retaining the door frame in a closedposition at the vehicle. The door frame includes a cap mounting portion.The cap assembly includes a connector for mounting the cap assembly tothe cap mounting portion of the door frame. The cap assembly furtherincludes an exterior rearview mirror and/or a handle assembly.

Preferably, the cap assembly includes an exterior rearview mirror, whichmay be engagable with an adjustment device of the door assembly, suchthat the exterior rearview mirror is adjustable from within the vehicle.The adjustment device may be electrical and/or mechanical. Preferably,the handle assembly is mechanically engagable with the latch mechanismof the door assembly as the cap assembly is attached to the door frame.The frame may comprise a metallic material, while the cap assemblycomprises a polymeric material. Preferably, the cap assembly isattachable to the door frame via a snap-fit connection and/or aplurality of fasteners.

In one form, the door assembly further includes a movable window whichis vertically adjustable via a window adjustment mechanism of the doorassembly. The cap assembly includes a window seal for engaging themovable window of the door assembly as the window is raised and loweredwithin the door frame.

In another form, the cap assembly includes a movable window assemblywhich is insertable within the door frame and connectable to a windowmechanism of the door assembly as the cap assembly is attached to thedoor frame.

Preferably, the door frame and door assembly are manufactured at a doormanufacturing plant, while the cap assembly is manufactured remote fromboth the door manufacturing plant and the vehicle manufacturing plant.The cap assembly is attachable to the door frame at the door or vehiclemanufacturing plant. Preferably, the cap assembly is colored to match anappropriate color of the door or trim of the vehicle.

According to yet another aspect of the present invention, a method ofassembling a door assembly of a vehicle comprises the steps ofassembling a door frame at a door manufacturing line or plant,assembling a cap assembly to the door frame at a vehicle assembly plant,and assembling the door frame to the vehicle at the vehicle assemblyplant. The cap assembly may include an exterior rearview mirrorassembly, a handle assembly, a window seal, and/or a movable windowassembly.

According to another aspect of the present invention, a cap assembly formounting to a door frame of a modular door assembly for a vehiclecomprises a cap member and an exterior rearview mirror, a window frameportion, and/or a handle assembly. The modular door includes a mountingregion along an upper portion of the door frame and may further includeat least one hinge component, a latch mechanism for releasably retainingthe door frame in a closed position at the vehicle, and a mirroradjustment device. The cap member is securable to the mounting region ofthe door frame. Preferably, the exterior rearview mirror and/or handleassembly are connectable to a connecting portion of the modular doorassembly as the cap member is secured to the door frame. The connectingportion provides connection of the mirror assembly to the mirroradjustment device and of the handle assembly to the latch mechanism. Inone form, the cap member comprises an upper cover which is attachablealong the upper mounting portion of the door frame. In another form, thecap member comprises an outer door panel and is attachable to an outersurface of the door frame.

Preferably, the exterior rearview mirror is connectable to electricalconnectors for electronically connecting at least one electroniccomponent and/or accessory, such as an electronic mirror adjustmentdevice, security lights, signal lights, or the like, of the exteriorrearview mirror assembly to a vehicle wiring. Preferably, the modulardoor is remotely assembled from a vehicle assembly line, while the capassembly is mountable to the modular door frame on the vehicle assemblyline.

According to yet another aspect of the present invention, a vehicularmodular door system comprises a door assembly for attaching to thevehicle and an exterior accessory assembly or module. The door assemblyincludes a door frame, at least one hinge member and a mounting portion.The exterior assembly includes at least one connector for mounting theexterior assembly to the mounting portion of the door assembly and atleast one of an exterior rearview mirror, a cap member extending over anupper portion of the door assembly, and a window frame.

In one form, the exterior assembly comprises the exterior rearviewmirror and is connectable to a mirror mount at the door assembly. Inanother form, the exterior assembly comprises the cap member, whichfurther includes an exterior rearview mirror and/or a door handle, andis mountable along an upper portion of the door assembly. Preferably,the exterior assembly is connectable to the mounting portion of the doorassembly via mechanical and electrical connectors which mount theexterior assembly to the door assembly and which provide power and/orcontrol to one or more accessories of the exterior assembly, such as amirror actuator, a security light, or the like. Optionally, the exteriorassembly may include the window frame, which may further include one ormore seals and/or a fixed and/or movable window and associated tracks.The frame and seals extend at least partially around a perimeter edge ofthe window or windows associated with the door assembly and/or theexterior assembly.

Preferably, the door frame and door assembly are manufactured at a doormanufacturing line, while the exterior assembly is manufactured remotefrom both the door manufacturing line and the vehicle manufacturingline. The exterior assembly is attachable to the door frame at the dooror vehicle manufacturing line. Preferably, the exterior assembly iscolored to match an appropriate color of the door or trim of thevehicle.

According to another aspect of the present invention, a method forassembling a vehicle door comprises assembling a door module or assemblyat a door assembly line, providing an exterior assembly, and assemblingthe exterior assembly to the door assembly at either the door assemblyline or a vehicle assembly line. The door assembly includes a frame, apanel, at least one hinge member, a latch mechanism and a mountingportion at the door frame. The exterior assembly includes a cap member,a door handle, an exterior rearview mirror assembly, a window frame, awindow seal, a fixed window and/or a movable window. The exteriorassembly is mountable to the mounting portion of the door frame whilethe door handle, exterior rearview mirror assembly, and/or movablewindow are connected to corresponding connectors of the door assembly.

Preferably, prior to assembling the exterior assembly to the doorassembly, the method includes providing the door assembly to a vehicleassembly line and assembling the door assembly to the vehicle at thevehicle assembly line. The exterior assembly is then assembled to thedoor assembly at the vehicle assembly line.

Therefore, the present invention provides for improved manufacturing ofdoors for various applications of common door frames. The presentinvention provides an exterior accessory module or assembly, such as anexterior rearview mirror assembly and/or a cap or cover assembly, whichis attachable to a portion of the door panel or door frame and ispreferably colored to match an appropriate cover or trim color of thevehicle door. The exterior cap assembly may include a door handle,exterior rearview mirror assembly and/or window assembly, which mayfurther include the window tracks, seals and frame for a movable and/orfixed window of the door, which are connectable to the appropriateelectrical and/or mechanical devices of the door frame as the exterioror cap assembly is secured to the door frame. The door assembly may thenbe manufactured as a common door, and the exterior assembly, or rearviewmirror assembly or cap assembly, may be snapped onto the door at thevehicle assembly line or at a just-in-time facility, and thusaccommodate different options, such as exterior rearview mirror optionsand door handle options, for the vehicle. Additionally, the exteriorassembly may include at least a portion of an exterior panel of thedoor, which may be the last item or component installed to the door orthe first item removed from the door for service. The present inventionthus enhances both the assembly and service processes, because theexterior panel provides access to the components of the door from the eterior side of the door. The exterior assembly of the present inventionthus provides improved assembly and service processes at the vehicleassembly plant and reduces the number of parts required to mount thevarious components/accessories to the door of the vehicle.

These and other objects, advantages, purposes and features of thisinvention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a view of an exterior rearview mirror, looking forwardlytoward a front of a vehicle having a modular door in accordance with thepresent invention;

FIG. 2 is a view similar to FIG. 1 of a foldable mirror assembly formounting to a modular door on a vehicle

FIG. 3 is an exploded perspective view of a cap assembly and door framein accordance with the present invention;

FIG. 4 is an exploded view similar to FIG. 3, with the cap assemblyincluding an exterior rearview mirror and a door handle;

FIG. 5 is a sectional view taken along the line V-V in FIG. 3;

FIG. 6 is a sectional view similar to FIG. 5 of a cap assembly of thepresent invention being mounted to an alternate door frame design;

FIG. 7 is a perspective view of a cap assembly of the present inventionwhich includes an exterior rearview mirror mounted toward an endthereof;

FIGS. 8A-8C are perspective views of alternate embodiments of capassemblies having different door handle components;

FIG. 8D is a lower plan view of the cap assembly of FIG. 8C;

FIG. 9 is a perspective view of another cap assembly of the presentinvention, which includes a door handle, an exterior rearview mirror,and a movable window assembly;

FIG. 10 is an exploded perspective view similar to FIG. 3 of another capassembly embodiment, which provides an exterior door panel for the doorassembly;

FIG. 11 is a perspective exploded view of an accessory module and doorassembly in accordance with the present invention;

FIG. 12 is a perspective view of a mirror module useful with theaccessory module of FIG. 11;

FIG. 13 is a perspective view of accessory modules for use along thefront and rear doors and the sides of a vehicle;

FIG. 14 is a cross sectional view of the window seals and frame of thepresent invention taken along the line XIV-XIV in FIG. 13;

FIG. 15 is a perspective view similar to FIG. 13 of another embodimentof the present invention;

FIG. 16 is a perspective view similar to FIGS. 13 and 15 of yet anotherembodiment of the present invention;

FIG. 17 is a cross sectional view of a door handle assembly taken alongthe line XVII-XVII in FIG. 16;

FIG. 18 is a side elevation of an alternate embodiment of the presentinvention, as installed on a vehicle door;

FIG. 19 is a side elevation of the module of FIG. 18 removed from thedoor;

FIG. 20 is an exploded perspective view of another embodiment of amodule in accordance with the present invention;

FIG. 21 is an enlarged perspective view of a portion of the module ofFIG. 20; and

FIG. 22 is a cross sectional view of the seals and frame between a fixedand movable window of the module, taken along the line XXII-XXII in FIG.19.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now specifically to the drawings, and the illustrativeembodiments depicted therein, a vehicle door module 10 is mounted to avehicle (not shown) and includes a mirror body mount 14 on an exteriorside 10 a of modular door 10 (FIG. 1). An exterior accessory module orassembly, such as exterior mirror head or body 16, is connectable tobody mount 14. Mirror body 16 and mirror body mount 14 arecorrespondingly formed for easy connection of mirror body 16 to bodymount 14 after modular door 10 is assembled and, more preferably, aftermodular door is installed on the vehicle at the vehicle assembly plant.Preferably, the door assembly includes an exterior mirror connectingassembly or system 13, which includes a connecting portion or element 14a at mirror body mount 14 and a connecting portion or element 16 a atmirror body 16, whereby mirror body 16 is mountable to body mount 14 viaconnection of the respective connecting portions from an exterior sideof the vehicle door assembly. The body mount 14 preferably includes aconnecting portion 14 a which snaps or otherwise easily attaches to acorrespondingly formed connecting portion 16 a of mirror body 16.Preferably, connecting portions 14 a and 16 a include correspondinglyformed electrical connectors or elements 14 b and 16 b to facilitateeasy connection of one or more electronic accessories 17 within mirrorbody 16 to a wiring 18 which is connected to a door wiring harness (notshown) within door module 10. Most preferably, electrical connectors 14b and 16 b are integrally molded within their respective connectingportions to provide substantially rigid current carriers molded withinthe plastic connecting portions.

Modular door 10 may be manufactured remotely from a vehicle assemblyplant, such as at a door manufacturer assembly plant or the like, andshipped as a single unit to the vehicle assembly plant for installationonto a vehicle body as the body travels along the assembly line. Modulardoor 10 may include one or more door accessories, such as windows,window control mechanisms, handles, lock mechanisms, regulators,interior and exterior trim components, interior or exterior lights,audible sources such as speakers, and/or the like. Modular door 10 mayfurther include interior controls or switches, such as controls forpower windows, power locks, power seats, power mirrors, interior cabinclimate or temperature settings and the like. Modular door 10 furtherincludes a door wiring harness (not shown) and/or a doorelectrical/electronic distribution network for electronically connectingthe electronic components and accessories of modular door 10 to avehicle wiring (not shown) within the vehicle.

Modular door 10 preferably includes mirror body mount 14 on a sail ortrim piece 12 on its exterior side 10 a. Mirror body mount 14 protrudesoutwardly from sail 12 or side 10 a for mounting mirror 16 thereto.Mirror body mount 14 may be painted to match the body color of thevehicle, or may be black or trim colored. Mirror body mount 14 includesconnecting portion 14 a, which is preferably a snap fit type connectorfor snapping or otherwise fixedly securing within a receiving connectingportion 16 a of mirror body 16. For example, as shown in FIG. 1,connecting portion 14 a may be a male connector which may include tabsor arms 14 c for engaging corresponding slots or openings 16 e in afemale connecting portion 16 a to positively secure mirror body 16 tobody mount 14 on modular door 10. Preferably, mirror body mount 14further includes electrical wiring connector 14 b for connecting tocorresponding connector 16 b on mirror body 16 to provide electricalpower and/or control to one or more accessories 17 within mirror body16.

Mirror body 16 comprises a housing 16 c and a reflective element 16 dadjustably positioned within housing 16 c. Connecting portion 16 a ispreferably formed within housing 16 c and correspondingly formed toreceive or otherwise engage connecting portion 14 a of body mount 14therein. Preferably, connecting portion 16 a receives mountingconnecting portion 14 a therein and snaps or otherwise positivelysecures to body mounting portion 14 to retain mirror body 16 to modulardoor 10 of vehicle 12. Although shown and described as a male and femaletype connector, the scope of the present invention clearly includesmirror body 16 and body mount 14 connecting via any other known means,such as one of the components including multiple push pins or tabs orthe like extending to engage corresponding receiving portions oropenings in or on the other component. It is further envisioned that themirror body 16 may otherwise be secured to body mount 14 by one or morescrews, fasteners, snaps or the like, without affecting the scope of thepresent invention.

Mirror body 16 may further include electrical connector 16 b which isengagable with electrical connector 14 b on body mount 14 as mirror body16 is affixed to body mount 14, in order to provide power and control tothe electrical accessory or accessories 17 of the mirror body 16.Preferably, connectors 14 b and 16 b are conventional multi-pin plug andsocket connectors which plug or telescope together to positively securethe door wiring 18 to one or more mirror wirings within the mirror heador body 16. Most preferably, the connectors are fixedly secured withinthe respective connecting portions 14 a and 16 a, such that as mirrorbody 16 is snapped or otherwise affixed to body mount 14, the electricalconnectors 14 b and 16 b are also snapped together. However, theelectrical wirings may be any known electrical wiring means, such asdata wires, a plurality of individual wires, or the like and may beconnected individually or by any known connecting means, such as otherterminal connectors or by clamping or crimping the wires together or thelike, without affecting the scope of the present invention.

Preferably, modular door 10 includes a mirror body mount having astandard mounting or connecting portion which is implementable on manydifferent modular doors for different applications. The mirror body 16then may be provided with a corresponding standard mounting orconnecting portion, such that the mirror body may be mountable onmodular doors for different vehicles or applications, thereby lesseningparts proliferation of mirror heads within the mirror manufacturerassembly plants and mounts or mounting portions within the modular doorassembly plants. The electrical connectors 14 b and 16 b would likewisepreferably be uniformly applied, standard connectors, such as multi-pin,plug and socket type connectors or the like.

Referring now to FIG. 2, an exterior mirror body 16′ may be a foldingmirror, such that the mirror body portion 16′ is pivotally mounted to abody mounting portion 14′ on a sail or trim piece 12′ or on an exteriorside 10 a′ of a modular door 10′ and is pivotable relative to thevehicle between an operative position and a folded position. Similar tomirror body 16 discussed above, mirror body 16′ comprises a housing 16c′ and a reflective element 16 d′ adjustably positioned within housing16 c′. Body mount 14′ may include a spindle or shaft 20, which isrotatably received within mirror body 16′ as mirror body 16′ is affixedto body mount 14′. The shaft 20 may include locking tabs or the like torotatably engage a corresponding passageway 16 a′ of mirror body 16′ andsubstantially preclude removal of mirror body 16′ relative to body mount14′, while allowing relative rotation therebetween. Shaft 20 mayalternately be included within or extending from housing 16 c′ of mirrorbody 16′ and engage a correspondingly formed passageway in body mount14′, without affecting the scope of the present invention.

Mirror body 16′ may further include one or more electrical accessories17′. Accordingly, mirror body 16′ may include an electrical element orconnector 16 b′ and wiring for electrical connection to a correspondingelement or connector 14 b′ at body mount 14′. Optionally, andpreferably, the wiring can be in the form of substantially rigidelectrical conducting pathways (such as formed from metal stampings orthe like) that are integrally molded, as is known in the molding arts,into the structure of the mirror body 16′ and/or the body mount 14′.Similar to electrical connectors 14 b and 16 b, discussed above,electrical connectors 14 b′ and 16 b′ may be any known electricalconnecting means, such as conventional multi-pin plug and socketconnectors or the like.

Mirror body 16′ may be a powerfold mirror, and may include an electronicpowerfold mirror actuator (not shown) within housing 16 c′. The actuatormay be a conventional actuator, as is well known in the automotivemirror art. The actuator may be actuated from within the vehicle and isoperable to engage a portion of spindle 20 or body mount 14′ to causemirror body 16′ to pivot relative to body mount 14′. Alternately, theactuator or motor may be mounted within mirror body mount 14′ on modulardoor 10′ and be operable to engage a portion of mirror body 16′, withoutaffecting the scope of the present invention. Although shown anddescribed as mirror body 16′ or body mount 14′ including a spindle whichis received on the other component, clearly other pivotable attachingmeans may be implemented, such as a portion of a hinge member beingpositioned on the mirror body 16′ with a corresponding second portion ofthe hinge on the mirror body mount 14′, without affecting the scope ofthe present invention. The hinge members may snap together or beconnected by a hinge pin or the like, or by any other known means. Theactuator may be positioned on either the mirror body 16′ or the mirrorbody mount 14′ in applications where the mirror is a powerfold mirror.

Mirror head or body 16 or 16′ may include one or more electronicaccessories 17 or 17′, such as reflective element positioning devices orsystems, such as disclosed in commonly assigned U.S. Pat. No. 5,796,176,issued to Kramer et al., the disclosure of which is hereby incorporatedherein by reference, lights, such as turn signals or security lights,such as disclosed in U.S. Pat. No. 5,371,659, filed Feb. 1, 1993 byPastrick et al., U.S. Pat. No. 5,497,306, filed Apr. 21, 1995 byPastrick, U.S. Pat. No. 5,823,654, filed Jul. 26, 1996 by Pastrick etal., and U.S. Pat. No. 5,669,699, filed Jan. 8, 1996 by Pastrick et al.,the disclosures of which are hereby incorporated herein by reference,and as disclosed in commonly assigned, co-pending U.S. patentapplication Ser. No. 09/102,414, filed Jun. 22, 1998 by Pastrick et al.,now U.S. Pat. No. 6,176,602, and Ser. No. 09/335,010, filed Jun. 17,1999 by Pastrick et al., now U.S. Pat. No. 6,276,821, the disclosures ofwhich are hereby incorporated herein by reference, variableelectrochromic reflective elements, such as disclosed in commonlyassigned U.S. Pat. No. 5,659,423, issued to Schierbeek et al., thedisclosure of which is hereby incorporated herein by reference, exteriortemperature sensors, cameras or sensors, such as disclosed in commonlyassigned U.S. Pat. No. 5,670,935, issued to Schofield et al., thedisclosure of which is hereby incorporated herein by reference, or thelike. In situations where a powerfold mirror is implemented, mirror body16′ may further include an electronic motor for pivoting mirror body 16′relative to body mount 14′, such as a conventional powerfold actuator,or an actuator of the type disclosed in commonly assigned, co-pendingU.S. patent application Ser. No. 09/408,867, filed Sep. 29, 1999 byWhitehead, now U.S. Pat. No. 6,243,218, the disclosure of which ishereby incorporated herein by reference. The electronic accessories areconnectable to the vehicle wiring through one or more connectors withinmirror body 16 or 16′. Each of the connectors are connectable tocorresponding connectors in the mirror body mount 14 or 14′, which isfurther connected to the vehicle wiring via door wiring harness 18.Preferably, mirror body 16 or 16′ includes a single standard connector16 b or 16 b′, which engages a corresponding standard connector 14 b or14 b′ in body mount 14 or 14′, respectively. A mirror wiring or harness(not shown) then connects each accessory to connector 16 b or 16 b′.

Providing the mirror head as a separate component from the modular doorfacilitates easier shipment of the modular door to the vehicle assemblyplant, since the mirror head no longer protrudes outwardly from themodular door. The mirror head may be shipped directly to the vehicleassembly plant and installed to the mirror mount after the modular dooris affixed to the vehicle. However, the mirror head may be shipped tothe modular door manufacturer and installed to the door prior toshipment, without affecting the scope of the present invention. Themirror head or body and body mount may be painted to match the vehiclecolor or may be black depending on the application.

Referring now to FIGS. 3-10, a modular door assembly 100 includes a doorframe 111 (FIGS. 3 and 4) and is mountable to a vehicle (not shown). Themodular door frame 111 includes a mounting region 112 for receiving anaccessory module or cap assembly 114 thereon. Cap assembly 114 includesa cap member 115, which is securable to mounting region 112 of doorframe 111 via any known fastening means, and may be formed to fit overvarious forms or shapes of mounting regions. Cap member 115 extendsalong an upper region of the door frame and provides at least a portionof an exterior surface or panel of the door. Cap member 115 may becolored to match an appropriate panel or trim color of the door and/orvehicle. Cap assembly 114 further includes a door handle 118, which ispivotable or movable to open the door of the vehicle from outside thevehicle, and/or an exterior rearview mirror assembly 120 (FIG. 4). It isfurther envisioned that cap assembly 114 may include an exteriorrearview mirror assembly 120, but no door handle (FIG. 7). Such a capassembly may be implemented on doors with door handles positioned loweron the door panels or above the cap assembly, such as the window framealong the rear perimeter edge of the door window. As cap member 115 issecured to mounting region 112 of door frame 111, door handle 118 ismechanically connectable to a door latch mechanism or linkage 122 withindoor frame 111, while exterior mirror 120 may be connectable to a mirroradjustment mechanism and/or to an electrical wiring of modular doorframe 111, as discussed below. As shown in FIG. 10, a cap assembly 314may include a cap member 315 which covers the entire door exterior as anexterior panel of the door, without affecting the scope of the presentinvention. Cap assembly 314 may further include a door handle 318, lockcylinder 327 and/or an exterior mirror assembly.

The door frame 111 and door module assembly may be manufactured remotelyfrom a vehicle assembly plant, such as at a door manufacturer assemblyplant or the like, and shipped as a single unit to the vehicle assemblyplant for installation onto a vehicle body as the body travels along theassembly line. Modular door frame 111 comprises a metal frame structureor an engineering plastic frame for the modular door, and includes aperimeter window frame 113 extending upwardly from cap mounting region112 to provide a perimeter seal around upper and side edges of a window132 (FIGS. 5 and 6) of the modular door. An external skin or panel (notshown), such as sheet metal or polymeric door panel, is attached to anouter portion 111 a of frame 111, while an interior panel (also notshown) and other trim components are attached to an interior portion 111b of frame 111. The modular door may also include one or more dooraccessories, such as hinged windows, window control mechanisms, lockmechanisms or devices 138, latch mechanisms 122, regulators, interiorand/or exterior trim components, interior and/or exterior lights,audible sources, such as speakers, and/or the like. Additionally, thedoor may further include interior controls or switches, such as controlsfor power windows, power locks, power seats, power mirrors, interiorcabin climate or temperature settings and the like. The door preferablyincludes a door wiring harness (not shown) and/or a doorelectrical/electronic distribution network for electronically connectingthe electronic components and accessories of the door to a vehiclewiring (not shown) within the vehicle.

Latch mechanism 122 of door frame 111 is connected to the door locks andlatches and is preferably accessible at a passageway 116 at cap mountingregion 112. Passageway 116 is positioned at a recess 126 in cap mountingregion 112 and provides access to the door latch mechanisms 122 suchthat door handle 118 of cap assembly 114 may be easily connected to doorlatch mechanisms or linkages 122 as cap member 115 is secured to capmounting region 112 of door frame 111. Recess 126 provides clearance fordoor handle 118 to be moved or pivoted to open the door assembly 100 ofthe vehicle. As shown in FIG. 4, door frame 111 may further include amirror or accessory connector 124 positioned toward a forward region ofcap mounting region 112. Accessory connector 124 may provide electricaland/or mechanical connection to cap assembly 114 and/or exteriorrearview mirror assembly 120 as cap member 115 is attached to capmounting region 112 of door frame 111, as discussed below.

Cap member 115 preferably comprises a polymeric material, and mayinclude a plurality of mechanical connectors 136 extending from an innersurface thereof. The mechanical connectors may be similar toconventional push or snap-fit connectors, such as Christmas treeconnectors or the like, which are engagable with a plurality ofcorresponding holes or openings in door frame 111 such that cap member115 may be fixedly secured to door frame 111 by pressing the connectorsthrough the openings and snapping the cap assembly to the door frame.The fasteners of cap assembly 114 may be integrally molded with the capmember to provide a single component, thereby reducing the number ofparts at the door assembly plant. In applications of cap assembly 314,the fasteners or connectors 136 may be positioned around a perimeter ofthe door panel 315 and/or at various locations within the perimeter tosecure the door panel 315 of cap assembly 314 to door frame 111.

Door handle 118 of cap assembly 114 is pivotably or movably mounted at arearward end 115 a of cap member 115. Door handle 118 includes anattaching portion 119, which is connectable to latch mechanism 122through passageway 116. Preferably, attaching portion 119 provides asnap together or similar quick connection of door handle 118 to latchmechanism 122 as cap member 115 is mounted to mounting region 112 ofdoor frame 111. Cap assembly 114 may also include a lock cylinder orlocking device 127 which is connectable to the locking mechanism 138 ofthe modular door assembly 110 as cap member 115 is mounted to door frame111. The lock cylinder or locking/unlocking device allows for a personto unlock the door of the vehicle from outside the vehicle, and maycomprise a mechanical key lock and/or an electrical keypad or the like.It is further envisioned that the locking device may comprise a solenoidoperable mechanism or electrical locking/unlocking mechanism, and mayinclude an automatic lock/unlock system that utilizes recognition of atransducer carried by an approaching operator and unlocks the door inresponse to such recognition. The locking device may optionally includea user recognition authorization system or device, which is operable tounlock the vehicle door in response to verification or identification ofthe user at the door, such as via recognition of the user's fingerprint(s), thermal profile, voice or the like.

Exterior mirror assembly 120 is mounted to a forward end 115 b of capmember 115. Exterior rearview mirror assembly 120 comprises a housing120 a and a reflective element 120 b adjustably positioned withinhousing 120 a. Mirror housing 120 a may be fixedly or pivotally securedto cap member 115 and may be color matched with the cap member toprovide a finished appearance to the cap assembly and to the modulardoor when the cap assembly is secured to the modular door frame 111.Preferably, cap member 115 includes a raised trim piece or sail 115 c atits forward end, such that mirror assembly 120 is attached at sail 115c. Sail 115 c then provides a finished appearance to the door as capassembly 114 is secured to door frame 111, such that sail 115 c covers aforward portion of door frame 111. Mirror assembly 120 may be a foldingmirror such that the mirror body or housing 120 a is pivotally mountedto the sail 115 c of cap assembly 114 and is pivotable relative to thevehicle between an operative position and a folded position, as is knownin the art.

Similar to mirror body 16 or 16′, discussed above, mirror assembly 120may include one or more electronic accessories, such as reflectiveelement positioning devices or systems, such as disclosed in commonlyassigned U.S. Pat. No. 5,796,176, issued to Kramer et al., thedisclosure of which is hereby incorporated herein by reference, lights,such as turn signals or security lights, such as disclosed in U.S. Pat.No. 5,371,659, filed Feb. 1, 1993, by Pastrick et al., U.S. Pat. No.5,497,306, filed Apr. 21, 1995, by Pastrick, U.S. Pat. No. 5,823,654,filed Jul. 26, 1996, by Pastrick et al., and U.S. Pat. No. 5,669,699,filed Jan. 8, 1996 by Pastrick et al., the disclosures of which arehereby incorporated herein by reference, and as disclosed in commonlyassigned, co-pending U.S. patent applications Ser. No. 09/102,414, filedJun. 22, 1998, by Pastrick et al., now U.S. Pat. No. 6,176,602, and Ser.No. 09/335,010, filed Jun. 17, 1999, by Pastrick et al., now U.S. Pat.No. 6,276,821, the disclosures of which are hereby incorporated hereinby reference, variable electrochromic reflective elements, such asdisclosed in commonly assigned U.S. Pat. No. 5,659,423, issued toSchierbeek et al., the disclosure of which is hereby incorporated hereinby reference, exterior temperature sensors, cameras or sensors, such asdisclosed in commonly assigned U.S. Pat. No. 5,670,935, issued toSchofield et al., the disclosure of which is hereby incorporated hereinby reference, and/or the like. In situations where a powerfold mirror isimplemented, the mirror assembly 120 may further include an electronicmotor for pivoting mirror body 120 a relative to cap member 115, such asa conventional powerfold actuator or an actuator of the type disclosedin commonly assigned U.S. patent application Ser. No. 09/408,867, filedSep. 29, 1999 by Whitehead, now U.S. Pat. No. 6,243,218, the disclosureof which is hereby incorporated herein by reference.

Preferably, cap assembly 114 further includes one or more mechanicaland/or electrical elements or connectors or connecting portions 121,which are preferably a snap-fit type connector for snapping or otherwisefixedly securing to the accessory connector 124 of door frame 111. Forexample, connecting portion 121 may be a male connector, which mayinclude tabs or arms for engaging corresponding slots or openings in afemale connector 124, in order to positively secure the adjustmentdevice of mirror assembly 120 to door frame 111. Accessory connector 124may include a mechanical mirror adjustment device, such as a cable orthe like, which may connect to a corresponding device within capassembly 114 and/or mirror assembly 120 to allow mechanical adjustmentof reflective element 120 b of the mirror assembly from within thevehicle. Where applicable, the accessory connector 124 of door frame 111and connector 121 of cap assembly 114 may include electrical wiring andconnectors to provide electrical power and/or control to electricalcomponents and/or accessories within mirror assembly 120 and/or capassembly 114.

Preferably, door frame 111 includes standard and/or common mounting orconnecting portions for both the mirror assembly or accessory connector124 and the door latch linkages 122 which are implementable on manydifferent door frames for different applications. Cap assembly 114 maybe provided with corresponding standard mounting or connecting portions,such that the cap assemblies may be mountable on modular doors fordifferent vehicles or applications, thereby reducing the number ofdifferent cap assemblies, door handles, and/or mirror assemblies withinthe cap assembly and/or door manufacturer assembly plants. Accessoryconnector 124 may be connected to a vehicle wiring (not shown) via adoor wiring harness (also not shown) in door frame 111. A mirror wiringor harness (not shown) then connects each accessory of cap assembly 114to the standard connector 121 of cap assembly 114. Optionally, andpreferably, the wiring may be in the form of substantially rigidelectrical conducting pathways (such as formed from metal stampings orthe like) that are integrally molded, as is known in the molding arts,into the structure of the mirror housing 120 a, the cap member 115,and/or the door frame 111. Alternately, the electrical connectors may beany known electrical connecting means, such as conventional multi-pin,plug and socket type connectors or the like, which plug together topositively secure a door wiring to one or more wirings within the mirrorassembly 120 or elsewhere within the cap assembly 114. Most preferably,the connectors are fixedly secured to the cap assembly such that as thecap assembly is snapped or otherwise secured to door frame 111, theelectrical connectors are also snapped together. However, the electricalwirings may be any other known electrical wiring means, such as datawires, a plurality of individual wires, or the like, and may beconnected individually or by any known connecting means, such as viaother terminal connectors or by clamping or crimping the wires togetheror the like, without affecting the scope of the present invention.

Cap assembly 114 may further include a window seal 130 (FIGS. 5 and 6)for engaging an exterior surface 132 a of a movable window 132 of themodular door. Window seal 130 may extend along an upper edge 115 d ofcap member 115, as shown in FIG. 5. Alternately, window seal 130 mayextend along upper edge 115 d of cap member 115, and may further seal orconnect to an upper edge 112 a of mounting region 112 of door frame 111(FIG. 6). Preferably, window seal 130 is molded onto upper edge 115 d,but may be otherwise secured, such as by clips or adhesive, withoutaffecting the scope of the present invention. As shown in FIGS. 5 and 6,cap member 115 may be modified to receive various seal and door framedesigns, without affecting the scope of the present invention.

As shown in FIGS. 8A-8D, cap assembly 114 may include various doorhandle designs, such as a door strap handle 118 a (FIG. 8A), a paddletype handle 118 b (FIG. 8B), or a hidden or partially covered/enclosedhandle 118 c (FIGS. 8C and 8D), or any other type of door handle. Thecap assembly for the hidden handle 118 c includes a cover or housing 128extending over door handle 118 c at recess 126 of the door frame.

Referring now to FIG. 9, a cap assembly 214 may include a cap member215, a door handle 218, a mirror assembly 220, and a movable windowinsert or cassette 240. The movable window cassette 240 preferablyincludes a window guide or frame 241 extending downwardly from capmember 215 and generally surrounding a movable window 232 when themovable window is lowered to a lowered position. Window cassette 240 maybe inserted within a modular door frame and secured therein, such thatmovable window 232 is vertically adjustable within the modular vehiculardoor. Preferably, movable window 232 includes a connecting mechanism ormember 242, which is connectable to a window adjustment mechanism (notshown) within the modular door frame, such that the movable window 232may be raised and lowered from within the vehicle via an electrical ormechanical device, as known in the art. Cap assembly 214 furtherincludes a window seal 244 extending along an upper edge 215 d of capmember 215. Window seal 244 engages an outer surface 232 a of movablewindow 232 as movable window 232 is vertically adjusted relative to capmember 215 and the vehicle door.

Similar to mirror body or head 16 or 16′, discussed above, providing thecap assembly with a mirror and/or handle as a separate component fromthe modular door facilitates easier shipment of the modular door to thevehicle assembly plant, since the mirror head no longer protrudesoutwardly from the modular door. The cap assembly with mirror head maybe shipped directly to the vehicle assembly plant and installed to thedoor frame after the modular door is affixed to the vehicle. This may beperformed after the internal components and external panels and/or trimhave been attached to the door frame. However, the cap assembly may beshipped to the modular door manufacturer or integrator and installed tothe door prior to shipment, without affecting the scope of the presentinvention. The cap member, handle, and/or mirror head or body may bepainted to match the vehicle color or may be black or other trim colordepending on the particular application.

Referring now to FIGS. 11 and 12, a vehicle door assembly 400 includesan exterior accessory module or assembly 410, which is mountable to avehicle door frame 412 and further includes a cap or cover member 415,an exterior mirror head 420 and sail 419, a door handle 418 and a lockcylinder or locking device 427, and a window trim or frame portion 450.Exterior assembly 410 preferably further includes a pair of windowtracks 452 extending downwardly from cap member 415 which guide amovable window 432 therealong. Preferably, exterior assembly 410 furtherincludes the seals for sealing the window 432 relative to cap member 415and frame 450, as discussed below.

Exterior assembly 410 is mountable to door frame 412 from an exteriorside of the frame, while one or more interior components, assemblies,cassettes, or modules 454 are mounted to the door frame 412 from aninterior side of the door frame. The interior assemblies 454 may includevarious components or accessories, such as speakers, motor mechanisms,door mechanisms, controls, side airbag units, and/or the like, and mayfurther include an interior trim panel for covering the interior surfaceof the door assembly 400. An exterior door panel 456 may be mounted todoor frame 412 adjacent to or immediately below cap member 415. Doorframe 412 comprises a stamped unibody frame, which includes a windowframe portion 413. A window raising/lowering mechanism or regulator 458may be provided or installed within frame 412 for raising and loweringthe movable window 432 along guides or tracks 452 of module or assembly410. The window may be movable via an electronic movable mechanism or amechanical mechanism. Alternately, or additionally, the exteriorassembly 410 may include a fixed window and/or an adjustable ventwindow, without affecting the scope of the present invention.

Preferably, exterior assembly 410 includes the seals for engaging andsealing the movable window along opening 415 f at cap member 415, andfurther along and within window frame 450 and guides 452 of exteriorassembly 410. The seals (not shown) along opening 415 f may beconventional window seals or the like, or may be similar to seals 130discussed above (but on both the exterior and interior sides of thewindow) and may be secured to cap member 415 or may be molded therewith,such as via a two shot molding process or the like. Similarly, the seals(also not shown) along frame 450 of exterior assembly 410 may be securedwithin a channel formed by frame 450, or may be molded with exteriorassembly 410, without affecting the scope of the present invention. Theframe and seals thus extend at least partially around a perimeter edgeof the movable window when the movable window is at least partiallyclosed.

Door handle 418 may be any type of door handle, such as a paddle typehandle, a strap handle or the like, and is movably mounted to cap member415 and connectable to a latch mechanism (not shown) within the doorassembly 400 as cap member 415 is mounted to door frame 412. Door handle418 may be positioned at a lower portion 415 e of cap member 415, suchthat cap member 415 may be a narrow trim panel or strip, yet is wideenough to receive door handle 418 at the lower portion 415 e. The doorhandle 418 and lower portion 415 e of cap member 415 are received withina recessed portion 412 d of door frame 412 when exterior assembly 410 ismounted to door frame 412. The locking device 427 may be a lockcylinder, a keypad, a solenoid operated device or other means forlocking/unlocking the door latch, as discussed above with respect tolocking device 127.

As exterior assembly 410 is mounted to the door frame 412, guides orchannels 452 of exterior assembly 410 are preferably inserted throughcorresponding openings 412 a at either end of a slot 412 c along anupper portion 412 b of frame 412, and slide along the edges of movablewindow 432 until cap member 415 seats against upper portion 412 b,whereby a slot 415 f along an upper region 415 d of cap member 415 isgenerally aligned with slot 412 c of door frame 412. Cap member 415 andframe 450 are then affixed to door frame 412 and window frame 413,preferably via a snap fit connection, such as via multiple connectors(not shown) at cap member 415 and frame 450 being inserted into and thusprotruding through and securing within corresponding openings orapertures 460 in door frame 412 and window frame 413, respectively.Alternately, it is envisioned that the window frame portion 450 ofexterior assembly 410 may provide the structural frame of the windowregion as well, such that the door frame 412 would not have to includethe window frame portion 413. The exterior assembly would then providethe rigid window frame of the door and the seals and channels for thewindow of the door and mount to an upper portion of a door body frame.Such a frame assembly is equally applicable to doors with movable and/orfixed windows. Preferably, as discussed above with respect to capassembly 115, as cap member 415 is secured to frame 412, the mechanicaland/or electrical connecting portions of door handle 418, lock 427and/or mirror 420 are correspondingly connected to appropriateconnectors at or within door frame 412.

Exterior assembly 410 is thus mounted to door frame 412 from outside thevehicle to improve the assembly processes of vehicle doors overconventional processes. The exterior module or assembly 410 may bemounted to frame 412 at the vehicle assembly plant as the vehicle anddoor frame travel along the vehicle assembly line, or may be mounted todoor frame 412 at a modular door manufacturer or door integrator plant,such as at a just-in-time (JIT), in sequence plant or line nearby thevehicle assembly plant or line. The exterior accessory module orassembly provides an integrated window, mirror and/or door handleassembly that is mechanically and/or electrically connectable to orloadable into the door frame or door module at the integrator's plant orline. The exterior assembly may include one or more electronic devices,such as lights, such as ground illumination lights, turn signal lights,side lights, running board lights (if the exterior assembly includes theouter door panel and a running board along a lower edge thereof) orother illumination sources, similar to those discussed above withrespect to mirror head 16 or mirror assembly 120 of cap assembly 114.The lights may be incandescent lights, light emitting diodes (LEDs) orother illumination sources, without affecting the scope of the presentinvention. As discussed above, exterior module or assembly 410 snaps orotherwise connects to door frame 412 such that both mechanical andelectrical connections are made to the door frame and appropriatecomponents or wirings/harnesses. The present invention thus providesmechanical, electrical, seal, window, exterior mirror and/or door handlemanagement to the integrator of the vehicle door assembly,

Optionally, the exterior panel 456 may be mounted to frame 412 in asimilar manner as exterior assembly 410, or may be included as a lowerportion of cap member 415, similar to cap assembly 314 discussed above,such that a single exterior cover assembly 410 is snapped or otherwisesecured to door frame 412 to provide the entire exterior surface andtrim of the door assembly 400. Also, exterior assembly 410 mayoptionally include a mirror mount or footer (not shown), such that aseparate mountable mirror assembly 420′ (FIG. 12) may be snapped orotherwise secured to the footer at the vehicle assembly plant. Thisprovides improved packaging of the door assembly for transporting thedoor to the vehicle assembly plant, since the mirror is not attacheduntil later and, thus, does not extend outwardly from the side of thedoor. The mirror assembly 420′ may include a sail portion 419′ and/or amirror head 420 a′ which is securable to exterior assembly 410 and/ordoor frame 412. Exterior mirror 420 or 420 a′ may be a fixed mirror, abreakaway mirror, a folding mirror, such as a powerfold mirror which iselectrically adjustable, such as of the type disclosed in commonlyassigned, co-pending U.S. patent application Ser. No. 09/408,867, filedSep. 29, 1999 by Whitehead, now U.S. Pat. No. 6,243,218, which is herebyincorporated herein by reference, or the like, and may include one ormore electrical accessories and/or mechanical adjustment devices,similar to mirror head 16, discussed above. Likewise, the connectingportions for the mirror head and the mount or footer at the exteriorassembly and/or frame are similar to those discussed above with respectto mirror head 16 and mirror mount 14.

As shown in FIGS. 13, 15 and 16, the exterior module or assembly of thepresent invention may be applied to a front door, a rear door with amovable window and a fixed window, and/or a rear panel of a vehicle,such as for a station wagon or a sport utility vehicle or the like. Eachof the exterior assemblies 510, 610 and 710 are substantially similar toexterior assembly 410, discussed above, such that a detailed descriptionof each assembly will not be repeated herein. Similar elements of theexterior assemblies have therefore been labeled with similar referencenumerals to exterior assembly 410, with an appropriate prefix (forexample 510, 610 or 710) added to the numbers.

Referring to FIGS. 13 and 14, a front door exterior module 510 a mayinclude an exterior mirror 520, a door handle 518 a, and/or a lockingdevice 527. The module 510 a may comprise a cap member 515 a and mayfurther include an upper, window frame portion 550 a which includes anupper portion 551 a, a forward leg portion 551 b and a rearward legportion 551 c. Additionally, frame portion 550 a preferably includes oneor more window seals for the movable window to slidably engage as thewindow is raised and lowered between an opened and closed position.

As shown in FIG. 14, upper portion 551 a of frame portion 550 a may beconnected to a window frame 513 of a door frame via engagement of one ormore slots 555 a, b with corresponding flanges or extensions 513 a, b ofwindow frame 513. Preferably, a compressible seal 553 a, b is providedwithin slots 555 a, b to seal the frame portion 550 a to the door frame.Upper frame portion 551 a is formed to engage the flanges and provide alower, interior surface 568 a and an outer trim surface 568 b around themetal of the door frame. Exterior assembly 510 a may thus be installedby aligning and engaging the slots 555 a, b with flanges 513 a, b andthen pressing the cap member 515 a onto the upper portion of the doorframe (not shown in FIG. 13), whereby connectors at cap member 515 a mayengage with and secure to corresponding openings or connectors at thedoor frame, until the cap member and thus exterior assembly 510 a issecured to the door frame.

Preferably, as shown in FIG. 14, the window seals for upper portion 551a of frame portion 550 a of exterior assembly 510 a comprise an upper,compressible seal 564 and an outer, multi-finger or multi-lip seal 566which slidably engages an outer surface 532 a of movable window 532 asthe movable window is raised to its closed position. Upper portion 551 afurther includes a guide portion 570 which extends partially into achannel 572 formed in upper portion 551 a for receiving movable window532 therein as window 532 is closed. Accordingly, as movable window 532is raised toward its closed position, an inner surface 532 b of window532 engages guide portion 570, which guides movable window 532 intochannel 572. Window 532 is thus aligned with channel 572 and engagesouter seal 566. Outer seal 566 flexes as it slidably engages outersurface 532 a of window 532 to substantially seal window 532 relative toframe portion 550 a of exterior assembly 510 a. As the window is raisedfurther, an upper edge 532 c of window 532 engages and compressescompressible seal 564 at an upper end of the channel 572. Similarly,other seals (not shown) are provided along the forward and rearward legportions 551 b, 551 c, to provide slidable engagement with outer surface532 a of movable window 532, thereby sealing window 532 relative toexterior assembly 510 a and thus the door assembly. Additionally, a pairof seals 594 are provided at either side of a slot in an upper portionof cap member 515 a. Movable window 532 is movable through the slot suchthat the interior and exterior sides of the window slidably engage arespective one of the lower seals along the cap member 515 a. Clearly,other means for sealing the movable window along the upper and sideportions 551 a, 551 b, 551 c of frame portion 550 a, and/or along thecap member 515 a, may be implemented to slidably seal the movable windowrelative to the frame portion 550 a, without affecting the scope of thepresent invention.

Similarly, a rear door exterior module 510 b, which is separate frommodule 510 a and rear panel cap assembly 510 c, may be mounted to a reardoor frame (not shown) and comprise a cap member 515 b and window frameportion 550 b, and may include a rear door handle 518 b (FIG. 13). Reardoor module 510 b may include a fixed window 574 and a movable window576, which are separated by a guide member or divider 578 b of windowframe portion 550 b. Window frame portion 550 b also includes a forwardleg member 578 a, a rear leg member 578 c and an upper member 578 d,which at least partially surround the fixed and movable windows ofexterior assembly or module 510 b. Preferably, exterior module 510 bincludes the window seals (not shown) for both windows and is formedaround fixed window 574 to substantially secure and seal the fixedwindow to the vehicle when module 510 b is installed at the appropriaterear door of the vehicle. The frame 550 b, divider 578 and associatedseals may be substantially similar to frame 550 a, discussed above,and/or to known frame and seal designs, or may be similar to thosedisclosed in commonly assigned, co-pending U.S. patent application Ser.No. 09/611,727, filed Jul. 7, 2000 by Davis et al. for VEHICLE WINDOWASSEMBLY, now U.S. Pat. No. 6,220,650, the disclosure of which is herebyincorporated herein by reference. Optionally, the frame may comprise atwo piece or “clamshell” type of frame which is securable togetheraround the fixed window and associated seals, as discussed below withrespect to FIGS. 18-22. Rear door exterior assembly 510 b is preferablymounted to the rear door frame in a similar manner as exterior assembly510 a or exterior assembly 410.

Additionally, a rear panel cap assembly 510 c, which is separate fromfront and rear door exterior modules 510 a and 510 b, may be providedalong a rear panel or portion of the vehicle, as shown in FIG. 13, Rearcap assembly 510 c includes a cap member 515 c, and may further includean upper, window frame portion 560 formed in one-piece with cap member515 c, which encases and seals a fixed window 562 and/or vent window(not shown) at the rear portion of the vehicle. Accordingly, the presentinvention may provide a generally continuous trim portion or panelextending along the doors and side of a vehicle. Similar to exteriorassembly 410, the separate exterior assemblies 510 a, 510 b and 510 care preferably secured to the respective portions of the door frames orvehicle frame from an exterior side thereof via a snap fit connection,whereby the mechanical and electrical connections are made for thevarious components as the assemblies are snapped or otherwise secured tothe frames of the doors and/or vehicle.

Referring now to FIG. 15, a front door exterior assembly 610 a and arear door exterior assembly 610 b, which is separate from front doorexterior assembly 610 a, may be mounted to a front and rear door frame(not shown), respectively. Front exterior assembly 610 a issubstantially similar to exterior assembly 510 a, discussed above. Frontexterior assembly 610 a includes a sail portion 619, which may includeexterior mirror 620 or may include a mirror mount or footing (notshown), at which a separate mirror head and/or sail is mounted in amanner similar to mirror head 16 and mirror mount 14 or mirror 420′,discussed above. Mirror 620 may be a fixed mirror, a breakaway mirror ora power folding mirror, as discussed above with respect to mirror head16, without affecting the scope of the present invention.

Cap member 615 a of exterior assembly 610 a includes a keypad 680, whichis operable to unlock the door in response to the appropriate sequenceof numbers or characters being touched or pressed at the keypad, as isknown in the art. The electrical connection of keypad 680 to a doorwiring harness (not shown) is provided in a similar manner as discussedabove with respect to cap assembly 114, such that the electricalconnection of keypad 680 (and any other electrical accessories includedin exterior assembly 610 a, such as lights, actuators, electrochromicdevices and the like of mirror 620, or lights or the like for doorhandle 618 a and/or lock 627) is made to corresponding connectors at thedoor frame (which, in turn, are connected to the door wiring and to thevehicle wiring) as the exterior assembly is mounted or snapped to thedoor frame.

Rear door exterior assembly or module 610 b is substantially similar toassembly 510 b, discussed above, and includes a cap member 615 b, a doorhandle 618 b, and an upper, window frame and seal portion 650 b, whichsubstantially surrounds and encases a movable window 676 and a fixedwindow 674. Window frame portion 650 b includes a front leg portion 678a, a divider or guide member 678 b, a rear leg portion 678 c and anupper portion 678 d. Each of the portions 678 a, 678 b, 678 c and 678 dof window frame portion 650 b, and an upper portion 615 c of cap member615 b, include appropriate seals for engaging and sealing movable window676 and/or fixed window 674 relative to exterior assembly 610 b. Asdiscussed above, the seals may be of known designs, or may be similar tothe seals of exterior assembly 510 b, or may be similar to the frame andseals disclosed in commonly assigned, co-pending U.S. patent applicationSer. No. 09/611,727, filed Jul. 7, 2000 by Davis et al. for VEHICLEWINDOW ASSEMBLY, now U.S. Pat. No. 6,220,650.

Another embodiment of an exterior assembly according to the presentinvention is shown in FIGS. 16 and 17 and includes a front door exteriorassembly 710 a and a rear door exterior assembly 710 b, which is formedseparately from front door exterior assembly 710 a. The cap members 715a, 715 b and window frame portions 750 a, 750 b are substantiallysimilar to the cap members and window frame portions discussed abovewith respect to exterior assemblies 410, 510 a, 510 b, 610 a and 610 b,such that a detailed discussion will not be repeated herein. Cap member715 a of front door exterior assembly 710 a includes a lower region 715e which provides an opening or aperture 715 g therethrough. A keypad 780is also positioned at lower region 715 e, such as above opening 715 g,as shown in FIG. 16. As seen in FIG. 17, the door handle 718 comprises apaddle portion 718 a and a pivot axle 718 b, and is positionedinteriorly of lower portion 715 e of cap member 715 a and within acavity defined by lower portion 715 e and an interior wall 715 i of capmember 715 a. Pivot axle 718 b of handle 718 is pivotably mounted at aninterior handle mounting portion 715 h of lower portion 715 e of capmember 715 a, such that paddle 718 a pivots about pivot mount 715 h aspaddle 718 a is pulled outwardly by a person opening the vehicle door.Handle 718 further includes a connecting portion 718 c, such as a springor hook, which extends from an inner side of paddle 718 a and protrudesthrough interior wall 715 i of cap member 715 a. The connecting portion718 c is preferably formed for easy connection, most preferably a snaptogether type connection, with a mechanical door latch mechanism orlinkage (not shown) within the vehicle door, whereby pivotal movement ofpaddle 718 a causes a corresponding movement of the latch mechanism orlinkage to release the latch and open the vehicle door.

As shown in FIG. 17, keypad 780 may be positioned at an outer surface oflower portion 715 e of cap member 715 a, such that electricalconnections 715 j to the keypad are preferably routed or molded withincap member 715 a to a connecting portion (not shown) of the cap member.Preferably, all of the electrical accessories included in exteriorassembly 710 a are connected, either via wiring harnesses or electricalconnectors molded within cap member 715 a, to one or more electricalconnectors at an interior surface of exterior assembly 710 a, such asalong cap member 715 a. The electrical connector (or connectors)preferably provides a snap connection or plug/socket connection, such asa multi-pin plug or socket or the like, to a corresponding plug orsocket at the door assembly.

As best seen from FIG. 17, an upper portion of cap member 715 a includesan outer portion 715 d′ and an inner portion 715 d″, which togetherdefine a gap 715 f therebetween for the movable window (not shown inFIG. 17) to pass therethrough. The upper portions 715 d′ and 715 d″preferably further include seals (also not shown in FIG. 17) or the liketo slidably engage the movable window as it is raised and lowered withinthe door assembly. The seals may be conventional seals or may be of thetype discussed above with respect to cap assembly 114, and may besecured along or molded with the upper portion 715 d of cap member 715a.

The door handle 718 and the upper portion of rear exterior assembly 710b for the rear door of the vehicle are substantially similar to the doorhandle and upper portion of front exterior assembly 710 a, discussedabove, such that a detailed discussion of rear assembly 710 b will notbe included herein.

Referring now to FIGS. 18-22, a rear door exterior assembly 810 ismounted to a rear door 800 of a vehicle, such as to a door frame asdescribed above. Exterior assembly 810 includes a lower, cap member orportion 815 and an upper, window frame portion 850 formed integrally andin one-piece with cap 815. Frame portion 850 includes a forward leg 882,a rearward leg 884, a divider or guide member 878 and an upper member886. A fixed window 874 is secured between divider 878, cap member 815,rear leg 884 and a rearward portion of upper member 886. Each of themembers 878, 884, 886 and 815 include window seals or the like (notshown in FIG. 18) for sealing fixed window relative to exterior assembly810. Similarly, window seals are provided along front leg 882, forwardportions of upper member 886 and cap member 815 and a forward edge ofdivider 878 for slidable or movable engagement with movable window 876as the movable window is raised and lowered between its opened andclosed positions. The seals and frame members may be formed as describedabove with respect to exterior assembly 510 a, or may be formed as a twopiece, snap together or “clamshell” frame, as discussed below.Alternately, however, the seals and window frame members or legs may beformed in other, known mariners, or may be formed as disclosed incommonly assigned, co-pending U.S. patent application Ser. No.09/611,727, filed Jul. 7, 2000 by Davis et al. for VEHICLE WINDOWASSEMBLY, now U.S. Pat. No. 6,220,650, without affecting the scope ofthe present invention. As shown in FIG. 18, exterior assembly 810provides a finished trim strip or panel along the upper portion of thevehicle door panel and around the windows of the door assembly, once itis installed to the door frame.

Referring to FIG. 19, exterior assembly 810 preferably includes a pairof lower window tracks or channels 852 and 853 which extend downwardlyfrom cap member 815 and guide the movable window therealong as thewindow (not shown in FIG. 19) is raised and lowered within the door.Preferably, channels 852, 853 of exterior assembly 810 are insertedwithin an opening in an upper portion of the door frame (not shown),prior to cap member 815 and window frame portion 850 snapping orotherwise securing to the door frame, similar to exterior assembly 410,discussed above and shown in FIG. 11.

Exterior assembly 810 may be formed as a two piece or clamshell frameassembly, whereby the two pieces are snapped together about the sealsand/or windows and may be interconnected via a living hinge 810 c or thelike, as shown in FIGS. 20-22. With reference to FIG. 20, exteriorassembly 810 comprises an outer portion 810 a and an inner portion 810b, which are connected along an upper edge via living hinge 810 c. Theouter and inner portions 810 a, 810 b pivot about hinge 810 c to aclosed or joined position, whereby the portions connect together to formexterior assembly 810, with the fixed window 874 and the window sealsfor the fixed window and movable window encased and secured therewithin,as discussed below. Preferably, the outer and inner portions 810 a, 810b and hinge 810 c are molded or formed of a polymeric material, asdescribed below, with the window seals (discussed below) being moldedwith the portions 810 a, 810 b, such as part of a two shot moldingprocess, or adhered or otherwise secured therealong using suitableadhesives or the like.

As best shown in FIG. 20, each of the outer and inner portions 810 a,810 b of exterior assembly 810 include corresponding outer and innerportions of rear leg member 884 a, 884 b, divider 878 a, 878 b, frontleg member 882 a, 882 b and upper member 886 a, 886 b, respectively. Theouter and inner portions 810 a, 810 b are preferably unitarily formed ormolded as a single unit joined at living hinge 810 c. Alternately,however, the outer portion 810 a may be molded separately from innerportion 810 b, and then the components may be aligned and snapped orotherwise secured together, such as by bonding, welding or securing viamechanical fasteners or the like, to form the exterior assembly 810,without affecting the scope of the present invention.

Similar to exterior assembly 510 a, exterior assembly 810 includes anupper compressible seal 864 positioned along an upper and forward regionof inner portion 886 b of upper member 886, and a flexible seal 866positioned along outer portion 886 a (FIGS. 20 and 21). Preferably,flexible seal 866 is unitarily formed with a forward leg seal 867 whichextends along outer portion 882 a of forward leg 882 and further alongouter portion 853 a of lower channel 853 for sliding engagement of aforward edge of movable window 876 as the window is vertically adjustedwith respect to the door assembly. Additionally, a similar flexible seal888 is provided along outer portion 878 a of divider 878 and furtheralong outer portion 852 a of channel 852, for sliding engagement with arearward edge of movable window 876. A fixed window seal 890 is alsoprovided along outer portion 878 a of divider 878, while a second fixedwindow seal 892 is provided along a rearward portion of outer uppermember 886 a and further along outer rearward member 884 a, for sealingengagement with an exterior surface of fixed window 874. Preferably,fixed window seals 890 and 892 are compressible, Y or U-shaped seals, asshown in FIGS. 21 and 22. Additionally, a pair of lower window seals 894a, 894 b (FIG. 20) are provided along cap member 815 for slidingengagement with the exterior and interior surfaces of movable window 876and for sealing of a lower edge of fixed window 874. The inner seal 894b may be secured along an inner portion (not shown) of cap member 815,or may be secured to an interior trim component of the vehicle door(also not shown).

As shown in FIG. 21, seal 866 is a flexible seal positioned along alower edge of outer upper portion 886 a, while seal 864 is acompressible seal or bead along an upper edge of inner upper portion 886b. Accordingly, when the outer and inner portions 810 a and 810 b ofexterior assembly 810 are closed together, the seals are positionedrelative to one another and to the movable window in a substantiallysimilar manner as seals 564 and 566, discussed above with respect toFIG. 14. Similarly, fixed window seal 892 extends along lower edge of arearward portion of outer upper member 886 a and along outer rearwardportion 884 a, such that fixed window seal 892 is compressed against anexterior surface of fixed window 874 when the exterior assembly 810 isclosed together about fixed window 874.

As best shown in FIGS. 21 and 22, outer divider portion 878 a includes aclasp or connector 896 extending generally along a center region ofouter divider portion 878 a, while inner divider portion 878 b includesa corresponding clasp or connector 897 extending along its centerregion. Connectors 896, 897 comprise tapered ends 896 a, 897 a, formingcamming surfaces which cause connectors 896, 897 to flex slightly asdivider portions 878 a, 878 b are pressed toward one another and theouter and inner portions 810 a, 810 b are closed together, and lockingsurfaces 896 b, 897 b, which engage one another after the connectors arepressed together and prevent separation of the outer and inner portions810 a, 810 b (FIG. 22). Similar connectors (not shown) may be providedalong the other members of the exterior assembly to further secure theouter and inner portions of exterior assembly 810 together. Innerdivider portion 878 b preferably further includes a raised, fixed windowcontact 898 and a pair of movable window contacts 899 a, 899 b, whichextend along opposite sides of connector 897 from fixed window contact898.

Movable window seal 888 and fixed window seal 890 extend along oppositesides of connector 896 on outer divider portion 878 a. Movable windowseal 888 is preferably a multi-fingered or multi-lipped seal havingthree fingers 888 a, 888 b, 888 c, while fixed window seal 890 ispreferably a Y-shaped seal having a pair of diverging lips or sealportions 890 a, 890 b, which flex as they are compressed against theexterior surface 874 a of the fixed window 874(FIG. 22). The outer edges879 a, 879 b of outer divider portion 878 a preferably providesubstantially flat surfaces which abut the movable window 876 and thefixed window 874, respectively, to provide a finished appearance todivider 878 when the assembly is closed about the windows (FIG. 22).

As shown in FIG. 22, when outer portion 810 a is mated with innerportion 810 b of exterior assembly 810, locking surfaces 896 b, 897 b ofconnectors 896, 897 engage one another to secure the outer and innerportions together along divider 878. Fixed window contact 898 on innerdivider portion 878 b engages the interior surface 874 b of fixed window874 to press window 874 toward seal 890 on outer divider portion 878 aand maintain fixed window 874 clamped within divider 878. Fixed window874 is thus secured within outer and inner portions 810 a, 810 b, withits exterior surface 874 a pressing against seals 890, 892 and a portionof lower seal 894 a, such that fixed window 874 is sealed along itsperimeter edges to substantially reduce wind and/or water intrusion intothe vehicle. Flat surface 879 b abuts against exterior surface 874 a offixed window 874 to conceal the seal 890 and provide a finished exteriorappearance to the window assembly.

Similar to fixed window 874, discussed above, movable window 876 issecured at least partially about its perimeter edges between the outerand inner divider portions 878 a, 878 b, except that movable window isslidably secured between the divider portions. As best seen in FIG. 22,when the divider portions 878 a, 878 b are secured together, movablewindow contacts 899 a, 899 b engage the interior surface 876 b ofmovable window 876 and press the exterior surface 876 a of movablewindow 876 into engagement with flexible seal 888, whereby the fingers888 a, 888 b, 888 c flex as they engage and slide along exterior surface876 a of movable window 876. Preferably, movable window contacts 899 a,899 b and seal 888 provide a low coefficient of friction surface toallow smooth sliding of movable window 876 therealong. Flat surface 879a of outer divider portion 878 a abuts or is slightly spaced fromexterior surface 876 a of movable window 876 to again conceal seal 888and provide a finished appearance to divider 878. An outer curvedsurface 881 a of outer divider portion 878 a and an inner curved surface881 b of inner divider portion 878 b provide a finished trim appearancefor the divider 878 from both the exterior and interior of the doorassembly when the exterior assembly 810 is mounted to the door frame.

Accordingly, when outer and inner portions 810 a, 810 b are securedtogether, exterior assembly 810 provides a finished trim appearance tothe window frame area of the rear door. The finished assembly, whichincludes the window trim region, the fixed window, and may include themovable window as well, and the window seals, may then be readilyinstalled into the door of the vehicle in accordance with the exteriorassemblies discussed above. The assembly may be installed at the doorassembly plant or at the vehicle assembly plant, without affecting thescope of the present invention.

Although shown and described as being implemented with an exteriorassembly or module for a vehicle door, it is further envisioned that aclamshell or two piece window frame assembly, utilizing aspects of innerand outer portions 810 b, 810 a of exterior assembly 810 discussedabove, may be equally applicable to an exterior front door or rear panelmodule or assembly of the present invention, or other non-modular windowframe assemblies, such as conventional frame and seal designs, or framesof the type disclosed in co-pending U.S. patent application Ser. No.09/611,727, filed Jul. 7, 2000 by Davis et al. for VEHICLE WINDOWASSEMBLY, now U.S. Pat. No. 6,220,650.

Accordingly, the present invention provides an exterior accessory moduleor assembly which is easily mountable to a vehicle door or frame at thevehicle assembly plant or at a modular door integrator's door assemblyplant or assembly line. The exterior assembly may comprise an exteriormirror body which is connectable to a mirror mounting portion of thevehicle door, a cap or cover assembly which is connectable along anupper portion of the vehicle door frame, and/or a window frame assemblywhich is connectable along a window portion of the door frame. Theassembly may include one or more accessories, such as an exteriorrearview mirror assembly, a door handle, a window mechanism, windowseals and/or the like, which are also connectable to appropriateconnectors or mechanisms of the door as the cap assembly is mounted tothe door. The exterior assembly or accessory module of the presentinvention is thus mountable to a vehicle modular door assembly andprovides one or more accessories for the door.

Preferably, the exterior accessory module or assembly, such as anexterior rearview mirror body or a cap or cover assembly, may besupplied to the vehicle assembly plant using just-in-time sequencingmethods, as is commonly known in the automotive supply art. Just-in-timeand/or sequencing techniques can be used to supply specific options,such as, for example, having an optional exterior rearview mirror, orpowered mirror adjusters versus manual adjustment of the reflectiveelement, (or having security lights within the mirror) for an individualvehicle as it passes down the vehicle assembly line. Thus, the vehiclemanufacturer can offer a wide array of options to a consumer from anoption menu. Should a specific customer select power mirrors or the likefor a particular vehicle due to be manufactured by the vehiclemanufacturer at a particular location on a specific day/hour, then themirror system supplier or other specialist supplier and/or cap assemblysupplier sends to the door or vehicle assembly line or plant, insequence and/or just in time, a mirror body assembly and/or a capassembly with a power adjustable exterior rearview mirror for thatparticular door or vehicle produced that day on the assembly line. Thedoor or vehicle manufacturer or door integrator may offer options forthe exterior rearview mirror which correspond to an optional interiorrearview mirror as well, such as an electrochromic mirror system, suchas disclosed in commonly assigned U.S. Pat. No. 5,424,898, issued toLarson et al., the disclosure of which is hereby incorporated herein byreference. The accessory module, such as an exterior rearview mirrorbody and/or a cap assembly and corresponding exterior mirror body and/orhandle may then be sequenced with the corresponding interior mirror fordoors or vehicles with that option.

Such just-in-time, in-sequence supply (which can be used for theincorporation of the various added features recited herein) is furtherfacilitated when the vehicle utilizes a car area network (CAN) such asdescribed in Irish Pat. Application No. 970014 entitled A VEHICLEREARVIEW MIRROR AND A VEHICLE CONTROL SYSTEM INCORPORATING SUCH MIRROR,application dated Jan. 9, 1997, the disclosure of which is herebyincorporated herein by reference, or when multiplexing is used, such asdisclosed in U.S. patent application Ser. No. 08/679,681 entitledVEHICLE MIRROR DIGITAL NETWORK AND DYNAMICALLY INTERACTIVE MIRRORSYSTEM, filed Jul. 11, 1996 by O'Farrell et al., now U.S. Pat. No.5,798,575, the disclosure of which is hereby incorporated herein byreference. Because the exterior accessory assembly may optionally beequipped with one or more accessories, it is useful to equip theassembly, cap, mirror body, and the mounting region of the door framewith standard connectors, such as for example, a ten-pin parallelconnector, such as electrical sockets or connections for receiving aplug connector, so that a common standard wiring connector can beprovided to the mirror mount on all of the modular doors. Naturally,multiplexing within the vehicle may help alleviate the need for morepins on such a connector, or may allow a given pin or set of pins tocontrol more than one function.

Also, the exterior assembly of the present invention encompasses manydifferent types of clip-on, snap-on or similar panels for attachment tothe frame of a modular door assembly; and with the cap assembly at leastincluding an external portion (such as an exterior mirrorcasing/exterior mirror reflector element) of an exterior rearview mirrorassembly and/or an external portion (such as a door handle) of a doorhandle assembly and/or an external portion (such as a keyhole) of a doorlock assembly. The exterior assembly of the present invention maycomprise a portion of a door exterior side panel (such as illustrated inFIGS. 3, 4, 7-11, 13, 15, 16 and 18) or may comprise substantially anentire door exterior side panel (such as illustrated in FIG. 10).

The mirror assembly, cap assembly or exterior assembly (or any componentthereof) is preferably molded from a polymeric material such as PC,PC/PBT, ASA, PP/ASA, an ionomer resin, a nylon resin, ABS, and the like.This may be painted [in which case, benefit can be had by pretreatingthe plastic resin in a priming/activating step (such as disclosed incommonly assigned, co-pending U.S. patent application Ser. No.09/489,322, filed Jan. 21, 2000 by Ten-Jen Chu, the disclosure of whichis hereby incorporated herein by reference) in order to enhance paintadhesion to the plastic body]. Alternatively, the mirror assembly capassembly (or any component thereof) can be formed by molding a coloredresin so as to obtain a molded-in-color part that is either body colormatched to the rest of the vehicle or that provides an accent color tothe rest of the vehicle. In this regard, molded-in-color resins such asBaxloy™ ionomer available from DuPont of Wilmington, Delaware can beused or Surlyn Reflection™ (an ionomer/nylon blend from DuPont), or W-4™which is a high-gloss, weatherable, solid color molding resin availablefrom GE Plastics. Such materials are preferably scratch resistant andweatherable (particularly to solar UV). Other materials suitable to use,and in particular for molded-in-black, high gloss mirror or capassemblies (and components thereof) include PMMA, PP/PMMA (HIVALLOY™from Montell), ASA (LURAN S™ from BASF or CENTREX™ from Bayer) andPC/PBT (Xenoy from GE). Note that components of the exterior assemblyand/or cap assembly (such as an exterior mirror housing or a doorhandle) can be made from the above materials. Also, where weight is aconcern, light-weight accessory module materials can be formed by foamedpolymer materials, and in particular foamed engineering plasticmaterials. Such foamed plastic moldings/parts can be formed such as bythe MUCELL™ process available from Trexel of Woburn, MA. In the MUCELL™process, as best understood, a gas (such as nitrogen or argon) is pumpedinto an injection mold while an assembly component or cap assembly isbeing molded, resulting in a multi-void “aerated” molded structure thatis light weight because of the multiple-voids introduced during themolding step. Use of such a MUCELL™ process to form light weight partsis useful such as for the mirror reflector-containing casings ofexterior mirror assemblies, the sail or mounting part of exterior mirrorassemblies, the minor reflector backing plates that attaches the mirrorelements of exterior mirror assemblies to their actuators, and for doorhandles.

Also, as an alternate to painting, such as spray painting to decorate amirror head or cap assembly or component thereof (such as the minorreflector-containing casings of exterior mirror assemblies, the sail ormounting part of exterior mirror assemblies, the mirror reflectorbacking plates that attach the mirror elements of exterior mirrorassemblies to their actuators, and the door handles), in-mold films(such as are disclosed in commonly assigned, co-pending U.S. patentapplication Ser. No. 09/564,665, filed May 1, 2000 by Tun-Jen Chu forCONSOLIDATED EXTERIOR SIDEVIEW MIRROR ASSEMBLY INCORPORATING AN IN-MOLDFILM PROCESS, now U.S. Pat. No. 6,310,738, the disclosure of which ishereby incorporated herein by reference) can be used for decoration.Such in-mold films (supplied in a variety of colors and finishes) allowa Class A decorative finish to be achieved on the MUCELL™—formed outerpart surface that typically, because of the aerated nature of itsformation that results in up to 40% weight saving compared tonon-aerated materials, has a poor surface quality that requiresdecoration. Note such in-mold film decoration of the parts isparticularly advantageous for MUCELL™ molded mirror reflector-containingcasings of exterior mirror assemblies, for the sail or mounting part ofexterior mirror assemblies, for the mirror reflector backing plates thatattach the mirror elements of exterior mirror assemblies to theiractuators, and for door handles. An alternate in-mold decorationtechnique suitable for these and for other components of cap assembliesis injection molding with paint such as the granular injection painttechnology available from Warwick University, UK. Also,multicomponent/multilayer molding, as known in the molding art, can beused for the mirror head assembly or the cap assembly (or any componentthereof). In multicomponent/multilayer molding, individual polymerresins are molded in a common mold to form a multilayer of a pluralityof separate and individual polymer material layers of the part. Inmultilayer molding, the polymer materials of the individual layers donot mix, and thus each individual layer retains its individual materialproperty and performance.

Also, when forming the modular door and/or the frame, the mirror mount,the mirror head, the exterior assembly and/or the cap assembly (and/orany component thereof), electrical connectors, conduits, supports,clips, fasteners, lead-frames, connectors and the like can be integrallymolded (as is known in the molding art) during the molding of themodular door frame and/or the exterior assembly (and/or any componentthereof). Also, electronic accessories, such as a passive entryantenna/device, a microwave antenna, a GPS antenna, an RF antenna, anAM/FM antenna, a remote keyless entry device, a remote transactiondevice, a video camera device (such as a blind spot monitoring videocamera), a security/ground illumination light, a turn signal light, akeyhole illuminating light (such as a light emitting diode) and/or aside indicator device and/or the like, can be included in the mirrorhead, the cap assembly (such as in a door handle or in an exteriormirror assembly), and/or along the window frame portion or door panelportion of the assembly, where applicable. In applications where theexterior assembly provides the entire exterior door panel, the panel mayfurther include a running board and lights therealong for illuminatingthe running board. Also, the cap assembly of this present invention cancomprise a rear door cap assembly, which may include a rear door handleand/or other accessories.

Using this present invention, a modular door manufacturer canmanufacture a modular door frame, with or without a window frameportion, and equip this with mechanical and electricalcomponents/connectors that connect with and/or connect to mechanicaland/or electrical components/connectors of the exterior assembly, suchas the rearview mirror assembly or the cap assembly (the cap assemblymay be supplied, optionally, to the modular door manufacturer by anothermanufacturer that specializes in exterior mirrors and/or door handles).In this regard, the connectors and methods disclosed above with respectto the mirror head and mount can be used to allow the exterior assemblyor cap assembly to attach to the modular frame. By using these concepts,the automaker can choose to buy a standard modular door frame from amodular door manufacturer. This modular door frame can then be equippedwith the desired color and feature content of the exterior mirrorassembly and/or the exterior door handle assembly of the accessorymodule either at the modular door manufacturing plant or at theautomaker assembly plant.

The exterior assembly, mirror assembly or cap assembly of the presentinvention is equipped with mechanical snaps and fasteners and withelectrical/electronic plugs, sockets and connectors so that when theaccessory module attaches to and mounts to the modular door frame,mechanical and/or electrical/electronic connections are made for theexterior mirror assembly and/or the exterior door handle assembly tocorresponding mechanical and/or electrical/electronic connectors,structures and/or devices of the modular door frame. This allows a “plugand play” capability that eases manufacture and reduces costs. It alsoreduces service complexity and cost in the field. Further, an exteriormirror assembly and/or sail of the cap assembly may mount to the capassembly in accordance with the connectors or mounting portions of themirror body 16 and mirror mount 14, discussed above. Preferably, thismounting is by a breakaway connection. The modular door frame may beformed of a metal material and/or of a high strength, structuralengineering polymer material or composite material, as known in thematerials art. Also, although preferably formed from a polymer orcomposite material, the exterior assembly or cap assembly (or anycomponent thereof) can be formed in whole or in part of a metal materialor a ceramic material.

Although described above as being installed to a vehicle modular door,aspects of the present invention are equally applicable to non-modulardoors as well. The exterior assembly, cap assembly or mirror head may bemounted to a door frame or mount of the non-modular door as the door isassembled at a door assembly line or at the vehicle along the vehicleassembly line. The modular door or the non-modular door assembly may beassembled at a door assembly line remote from the vehicle assemblyplant, such as at a door manufacturing plant, or along a door assemblyline at the vehicle assembly plant and generally alongside the vehicleassembly line, or on the vehicle as the vehicle moves along the vehicleassembly line.

Therefore, the present invention provides a door assembly whichfacilitates easy attachment of an exterior accessory module or assembly,such as an exterior rearview mirror or a cap assembly, which furtherincludes the door handle and/or exterior rearview mirror body, and whichmay also or otherwise include a window trim portion and associatedseals, after the door has been installed to the vehicle within thevehicle assembly plant. This provides an improved assembly process forassembling exterior accessories and trim to the vehicle door or doors.The exterior assembly mates with and readily connects to the modulardoor or door frame, while the accessories of the exterior assemblycorrespondingly mate with or readily connect to appropriate electricaland/or mechanical connectors or linkages at the door. The exteriorassembly may or may not include an exterior door panel as well. Theexterior door panel may then be the last component or item snapped ontoor otherwise secured to the door assembly during the assembly process,and may be the first item removed for servicing the door or componentsthereof and/or for replacing the exterior panel. This allows forsubstantially improved assembly and service processes, because thecomponents of the door assembly may be accessed from the exterior sideof the vehicle door via removal of the exterior panel. Additionally, theexterior panel may be replaced if it is damaged, without having toreplace the entire door assembly. The exterior assembly may bemechanically and/or electrically connected to a mounting region of themodular door while the vehicle travels along the assembly line.Preferably, the connecting portions for mechanically and electricallyconnecting the components together are standard/common connecting means,such that the exterior module, mirror and/or cap assemblies may beeasily mountable to one or more frames for various vehicle door designsand applications.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the invention,which is intended to be limited only by the scope of the appendedclaims, as interpreted according to the principles of patent law.

1. A mirror assembly for a vehicle, said mirror assembly comprising: areflective element portion; a molded portion; and wherein said moldedportion is formed of a multi-void, lightweight structure, saidmulti-void, lightweight structure being formed by injecting a gas intoan injection mold while said molded portion is being molded, resultingin a multi-void aerated molded structure having multiple-voidsintroduced during the molding step.
 2. The mirror assembly of claim 1,wherein said molded portion comprises at least one of (a) a housingportion of said mirror assembly, (b) a reflective element backplateportion of said mirror assembly and (c) a mounting portion of saidmirror assembly.
 3. The mirror assembly of claim 1, wherein said moldedportion is decorated via an in-mold film established at an outer surfaceof said molded portion during a molding process of said molded portion.4. The mirror assembly of claim 3, wherein said in-mold film provides aClass A decorative finish to be achieved on said outer surface of saidmolded portion.
 5. A window assembly for a vehicle, said window assemblycomprising: an outer frame portion; an inner frame portion, said innerframe portion being hingedly attached to said outer frame portion; atleast one sealing element established along a sealing portion of atleast one of said outer frame portion and said inner frame portion; andwherein said outer frame portion is pivoted relative to said inner frameportion and about said hinge portions to a closed position, said outerframe portion being connected to said inner frame portion when in saidclosed position to secure said at least one sealing elementtherebetween.
 6. The window assembly of claim 5 further comprising awindow panel at said sealing portion of said at least one of said outerframe portion and said inner frame portion, said outer frame portion andsaid inner frame portion cooperating to fixedly retain said window panelrelative to said outer and inner frame portions when in said closedposition.
 7. The window assembly of claim 5, wherein said outer andinner frame portions comprise polymeric frame portions and wherein saidhinge portion comprises a living hinge integrally molded with said outerand inner frame portions.
 8. The window assembly of claim 7, whereinsaid at least one sealing element is molded with at least one of saidouter and inner fame portions.
 9. The window assembly of claim 5,wherein said outer frame portion is connected to said inner frameportion when in said closed position via a snap connection.
 10. Thewindow assembly of claim 5, wherein each of said outer frame portion andsaid inner frame portion comprises an upper frame portion, a forwardframe portion and a rearward frame portion that cooperate to define atleast one window opening when said outer and inner frame portions are insaid closed position.
 11. The window assembly of claim 10, wherein saidwindow opening receives one of a fixed window panel and a movable windowpanel.
 12. The window assembly of claim 10 further comprising a dividerframe portion extending from said upper frame portion and extendingbetween said forward and rearward frame portions, and wherein said upperframe portion, said divider frame portion and said rearward frameportion cooperate to define a fixed window opening for receiving a fixedwindow panel therein when said outer and inner frame portions are insaid closed position, and wherein said upper frame portion, said dividerframe portion and said forward frame portion cooperate to define amovable window opening for movably receiving a movable window paneltherein when said outer and inner frame portions are in said closedposition.